Electric switch



July 13, 1943. R. POPP ET AL ELECTRIC SWITCH Filed Nov. 5', 1941 Patented July 13, 1943 ELECTRIC SWITCH Rudolf Popp and Marvin C. Carlson, Valparaiso,

Ind, assignors to McGill Manufacturing Cornpany, Valparaiso, End, a corporation of Indiana Application November 5, 1941, Serial No. 417,912

(Cl. 20ii6) Claims.

This invent on relates generally to electric switches and in particular to electric switches of multi-circuit type.

It is an object of this invention to provide an improved multiple circuit switch.

Another object of this invention is to provide a pull chain multiple circuit switch in which arcing or short-circuiting between the metal parts thereof is completely eliminated regardless of the operating voltage in the circuit which it conrols.

A further object of this invention is to provide a switch which is comprised of a minimum number of parts of simple design adapted to be quickly and inexpensively assembled into a compact unit of rigid construction.

Yet another object of this invention is to provide a pull chain switch for controlling a single circuit or a multi-branch circuit which is comprised of non-rusting parts providing for its smooth and efficient operation over a long service life with a minimum of attention.

A feature of this invention is found in the provision of a multi-circuit switch having terminal units which are completely preassembled prior to their assembly with the switch frame members.

Yet another feature of this invention is found in the provision of a switch including side plates having preassembled terminal units disposed therebetween, in which projections on the terminal units are inserted through the side plates and extended outwardly from each plate to receive an apertured jumper portion, the side plates being rigidly assembled in a spaced parallel relation by bending the projections inwardly toward the side plates.

Further objects, features and advantages of this invention will become apparent from the following description when taken in connection with the accompanying drawing in which:

Fig. 1 is a side view of the complete switch unit of this invention with one of the side plates removed to more clearly show the switch construction;

Fig. 2 is a transverse sectional view as seen along the line 22 in Fig. 1;

Fig. 3 is a fragmentary sectional View showing the assembly relation of a ternnnal unit with the switch side plates;

Fig. 4 is a perspective View showing the assernbly of a terminal unit; and

Fig. 5 is a perspective view of a jumper for connecting certain of the terminal units.

In the practice of this invention there is profor mounting with or without a hous ng and including a frame having a pair of insulating side plates and actuating means carried in the frame for operating a plurality of insulating stacked contact discs rotatable within a plurality of contact arms, with a set of arms for each contact disc and a corresponding terminal unit for each arm. The terminal units are angularly positioned about and between the frame side plates and are adapted to retain the side plates in a spaced parallel relation. Jumper members for connecting certain of the terminal'units are lo.- cated outwardly of the side plates. lhe side plates and the jumpers are provided with cone sponding apertures adapted to receive therein corresponding extensions or ears on the terminal units, with the side plates and terminal units being rigidly held in assembly relation by simply bending over the terminal unit extensions inwardly toward the side plates.

Referring to the drawing, the complete switch mechanism of this invention is illustrated in Figs. 1 and 2 as having a frame including side plates or frame members It), retained in a parallel spaced relation by terminal units ll disposed be.- tween the side plates and angularly spaced thereabout. As shown in Fig. 4, each terminal unit H is comprised of an insulating supporting or spacer member l2 inserted within an insulating portion l3 positioned transversely of the spacing member I2 and intermediate the ends there.- of. The spacer member i2 and separating portion l3 may be provided in a fibre or like material. Arranged in a superposed or stacked relation at each end of the terminal unit Ii and on opposite sides of the separating portion 53 are a spring-contact arm it, a conductor portion l5, and a soldering lug !'l.. Each end of the spacing member l2 and a corresponding groupof stacked elements are formed with aligned apertures adapted to receive therethrough a conducting eyelet Hi, the bending over of the eyelet ends serving to rigidly retain these corresponding elements in their superposed positions in an obvious manner. The terminal unit I I isthus completely preassembled prior to its assembly with the switch structure. Although the lugs l! are indicated as extending transversely of the terminal unit I i, it is apparent that they may be arranged longitudinally thereof within the scope of this invention.

In the assembly of a terminal unit II, the separating portion l3 may be utilized to center the corresponding end elements for stacking, the

vided a switch comprising switching mechanism 55 overall assembly of the unit being greatly facilitated by virtue of the aligned apertures being of a circular form, corresponding to the cross-sectional circular form of an eyelet I8. This construction eliminates any fumbling or relative maneuvering between an eyelet I8 and corre' sponding stacked elements, whereby to simplify and accelerate the terminal unit assembly.

The conductor portions l6 of each terminal unit I! are integrally formed with longitudinally extending ears or projections l9 which extend outwardly from each end of the spacing member l2, in the assembly of the terminal units with the side plates l0, these projections I9 are inserted through corresponding apertures 2| (Fig. 3) peripherally formed about the side plates 10. With the projections l9 extended through the plates, the inner surfaces of the plates H] are brought into engagement with corresponding ends of the spacer members I2. Since all of the spacer members l2 are similarly engaged by the side plates I 0, a spaced and parallel relation between the plates is obtained. The projections l9 are of a length to extend outwardly from the side plates l0 so as to receive thereon an apertured jumper member 22 which, as is well known in switches of this type, serves to electrically connect certain of the terminal units with a common lead line in the circuit to be controlled. As is best shown in Figs. 3 and 5, the jumpers 22 are of a fiat arcuate shape and fitted against the outer surface of a corresponding side plate. Retention of the side plates [0 in abutting engagement against the ends of the spacing members I2 is accomplished by bending the projections l9 over toward the side plates and against ment occurred between the terminal units and frame plates. This disadvantage is entirely overcome in the present invention because the side plates ID are rigidly retained in a fixed relative parallel position directly against the spacer members l2. From a consideration of Figs. 2 and 3 it is seen that the jumper members 22 are relatively thin so that all of the projections 19 are bent over substantially the same amount regardless of whether or not the are extended through a side plate alone, or a side plate and a jumper. 5

Since the jumpers are to the outside of the side plates, the plates are thus forced against the spacer members of all of the terminal units II and held rigid relative thereto. This manner of locating the jumpers 22 with the remaining switch structure in cooperation with the preassembly of the terminal units ll simplifies and quickens the complete switch assembly so as to appreciably reduce the overall cost thereof. It is evident also that the bending of the projections [9 directly against the jumpers 22 improves the electrical connection between a jumper member 22 and corresponding contact arms l4, this connection being completed through the clamped engagement of a contact arm l4 between a correspond- .M ing conductor member 4 6 and spacer member l2.

Each set of contact arms M at the corresponding ends of the terminal units H is operatively associated with an insulating contact disc or rotor 23 mounted near an end of a spindle or axis member 24 having end bearing portions 26 rotatably supported in the side plates I6. As shown in Figs. 1 and 2 the spindle center portion between the bearing portions 26 is of substantially square cross-section, with the discs 23 having corresponding square bores therein for fitting on this spindle center portion. The discs 23 are of similar construction and are peripherally formed with teeth 2? for engaging the free ends 28 of the spring contact arms l4. Each disc carries a bridging contact 29 having two contact portions 3| on oppositely disposed teeth 21 of a disc 23. A bridging contact 29 (Figs. 1 and 2) is provided with a substantially flat body portion which is positioned against one side of a corresponding disc and is retained thereon, in a usual manner, by bending inwardly integrally formed ears 32 into mating apertures 33 provided in the disc 23. A central opening 34 in the bridging contact 29 permits passage of the spindle 2d therethrough, the sides of the opening 3 2 being substantially adjacent the spindle, Since the discs 23 are of a similar construction the bridging contacts 29 in the assembly of the switch are positioned to corresponding sides of the discs 23.

Intermediate the discs 23 and mounted on the spindle 2 5 is a ratchet wheel 36 separated from the discs 23 by insulating washers 37. The ratchet 36 is comprised or a plurality of insulating laminations 38 which are stacked axially of the spindle 2:3. From a consideration of Fig. 2 it is evident that the spindl 24 is completely insulated from all of the conducting metal portions in the switch structure, and by virtue of the laminated insulating ratchet wheel 36 is also insulated from a pawl member 39 to be later described. The insulating washers 3'! extend beyond the periphery of the contact discs 23 to insulate the pawl member 39 from the ends 23 of the spring contact arms it. Any possibility of a short circuit occurring in the conducting parts of the switch is thus completely eliminated so that the pawl actuating mechanism may be safely operated at all times regardless of the operating voltage in the circuit which the switch controls. The laminated ratchet wheel may be easily and inexpensively manufactured and is readily varied in axial length for a particular switch by varying the number of laminations used in its construction. Since these laminations are formed by a stamping or punching out process burrs or outstanding edges may be left thereon without any danger or injury to the remaining insulating portions of the switch and specifically to the insulating washers 31.

Where metal laminationg are used burr left thereon by the stamping machine must be completely removed to provide for a smooth driving 1 action of the ratchet wheel 36 by the pawl 39. If the burrs are not removed, an efiicient return motion of the pawl as well as its proper engagement with a ratchet tooth 35 are greatly impaired. It is evident also that the falling 01? of a burr within the switch mechanism would in many instances provide for a short circuit thereof, such as for example the contact disc 29 to the spindle 24. The removal of these burrs from metal laminations necessitates a tumbling operation which serves to unnecessarily increase the overall cost of the switch unit. It is also evident that the maintenance of a punching die for metal laminatio-ns is much greater than that for a die for punching laminations from insulating material. Also in the use of metal laminations the tolerance of the center bore must be maintained relatively close to provide for a snug frictional fit about the spindle 24. On the other hand, the insulating laminations 38 may be machined with relatively wide tolerances since they are sufliciently flexible to be expanded for fitting over the spindle 24. By virtue of this action of the laminations 38 and their consequent tight frictional engagement withthe spindle 24, a rigid and substantially integral construction of the spindle and ratchet wheel 36 is accomplished with a minimum of cost.

The ratchet wheel 36, and in turn the switch mechanism, is actuated by a pull chain lever and operating mechanism including the pawl 39, previously mentioned, which is of a substantially U-shape and supported on a reciprocating pin M, with a coiled spring 42 surrounding the pin 4! and having one end bearing against the back of the pawl 39 as shown in Fig. 1. This structure is similar to that shown in Patent No. 1,974,054 to the applicant Popp. The other end of the spring 4! bears against an annular seat (not shown) provided in a one-piece combination frame support and mounting stem 43 which in turn is carried between the side plates l0. A cylindrical threaded portion 44 is provided on the mounting stem 43 to receive the usual threaded mounting nuts 45 for mounting the switch in a canopy, cut-out box or the like.

In the assembly of the switch structure, the discs 23, spindle 24 and ratchet wheel 36 assembly, terminal units II, and the lever actuating mechanism are placed in their relative positions with respect to the plates H) by bench operations. This assembly is then transferred to a suitable stampin or bending machine which is adapted to bend over the terminal unit projecting portions I9 toward the side plates It. Because of the preassembly of the terminal units H and the location of the jumpers 22 to the outside of the side plates, all assembly work is completed prior to the transfer of the switch structure to the bending machine. As a result the bending machine is operated with a minimum of lost time because the bench assembled switch structures can be fed continuously thereto. Since the operation of the bending machine appreciably increases production expense, its efiicient operation provides for a marked reduction in the selling cost of the switch.

In the use of the switch structure of this invention, a smooth and easy operation is accomplished by virtue of the insulating discs 23 and ratchet wheel 36 being composed of an insulating material. In the stamping of these parts their peripheries are formed with relatively smooth surfaces, so that a smooth frictional engagement occurs between th insulating discs 23 and ends 28 of the contact arms l4, and between the ratchet Wheel 36 and the pawl member 39. Since the pawl 39 and contact arms M are composed of a copper alloy which resists rusting, and with the insulating discs 23 and ratchet wheel 36 being composed of a non-rusting material, the switch is substantially unaffected by moisture so that its smooth operation is maintained over a long service life with a minimum of servicing.

From a consideration of the above description and drawings it is seen that the present invention provides a multi-circuit switch which is simple and rugged in construction and easily and quickly assembled at a minimum of cost into a compact and rigid unit. The construction of the terminal units providing for their complete assembly prior to their installation in the remainder of the switch structure reduces the overall cost of the switch by simplifying the assembly of the soldering lugs I! and facilitating the assembly of the terminal units with the side plates i5. The location of the jumper members 22 to the outside of the side plates 29 provides for the plates being rigidly retained in a fixed spaced parallel relation regardless of the number and location of the jumper members utilized in a particular switch structure. Since all of the switch parts are composed of a non-rusting material its initial smooth and easy performance is retained over a long operating life.

Although the invention has been described with reference to a specific embodiment thereof. it is to be understood that changes can be made therein which are within the full intended scope of this invention as defined by the appended claims.

W e claim:

1. An electric switch including in combination an insulating frame, a metal member rotatably supported in said frame, an insulating contact disc having metal contacts thereon, supported adjacent each end of said metal member, a metal contact-bridging member on each of said contact discs spaced from said metal member, an insulating ratchet wheel mounted on said metal member intermediate said two contact discs, metal actuating means mounted on said frame and associated with said ratchet wheel to rotate said metal member and said two contact discs therewith, and insulating means between said ratchet wheel and each of said contact discs, with said defined insulating parts insulating said metal actuating means from said metal member.

2. An electric switch having an insulating frame for supporting switch mechanism including a metal member rotatable in said frame, an insulating contact disc mounted near each end of said metal member, each of said two contact discs having metal contacts thereon, and a connector portion for said contacts spaced from said metal member, a ratchet assembly supported on said metal member comprising a plurality of insulating laminations stacked axially of said metal member and intermediate said contact discs, metal pawl means carried by said frame associated with said ratchet assembly to rotate said metal member and said contact discs therewith, and an insulating disc of greater diameter than said contact discs carried on said metal member between said ratchet assembly and each of said contact discs, said ratchet assembly and all of said insulating discs insulating said metal pawl means from said metal member.

3. An electric switch including a pair of like frame members having apertures spaced therein, switch mechanism carried by said frame members including terminal units, each of which has a conducting lug extending from the opposite ends thereof, said terminal units being positioned between said frame members to space the same in a parallel relation, and conducting members electrically connecting together certain of said terminal units positioned outwardly of said frame members, said conducting members having apertures therein arranged in a spaced relation corresponding to the apertures in said frame members, with all of said lugs being extended through said frame member apertures, and the lugs on said certain terminal units extending also through said conducting member apertures, with all of said lugs having a formed portion at the free ends thereof to maintain said conducting members, terminal units and frame members in a rigid assembly.

4. An electric switch including a frame having a pair of like side plates with corresponding apertures therein, means retaining said side plates in a spaced parallel relation including terminal units, each of which has a spacer portion, and an extension at opposite ends of said spacer portion, and a flat conducting member electrically connecting together certain of said terminal units positioned outwardly of and against each of said side plates, said conducting members having apertures therein, and said spacer portions being located between said side plates with the extensions thereon projected through the side plate apertures, with the extensions on said certain terminal units projecting also through said conductor member apertures, with the projecting end portion of an extension being extended laterally away from the corresponding body portion to hold said terminal units, conducting members and side plates in fixed relative positions.

5. An electric switch including a frame having a pair of side plates with corresponding apertures therein, a plurality of terminal units carried between said side plates and retaining the same in a spaced substantially parallel relation, each of said units including an insulating spacer member, an insulating portion having an opening therein, said spacer member being inserted through said opening, a contact arm, a conductor portion and a soldering lug arranged in that order in a superposed relation on each extending end portion of said spacer member and to opposite sides of said insulating portion, with a corresponding soldering lug, conductor portion and contact arm at each end of said spacer member having apertures therein in alignment with an aperture in a corresponding end portion of said spacer member, and an eyelet extended through said aligned apertures to retain said corresponding defined superposed elements in fixed relative positions, with each conductor portion having oppositely extending lug portions thereon projecting outwardly from a corresponding terminal unit, said lug portions being inserted through corresponding ones of said side plate apertures, and having their free end portions of a form adapted to maintain said terminal units and said side plates in fixed relative positions.

RUDOLF POPP. MARVIN C. CARLSON. 

